Blister package assemblies and systems and methods for producing said assemblies

ABSTRACT

Systems and methods package retail products and provide a sheet divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet. Further, the systems and methods load a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the window formed in the sheet. Moreover, the systems and methods fold the second part onto the first part to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.

CROSS REFERENCE TO RELATED APPLICATION

This application is a non-provisional application claiming the benefit under 35 U.S.C. 119(e) of U.S. Provisional Patent Application Nos. 62/054,679, filed on Sep. 24, 2014, and 62/212,304, filed on Aug. 31, 2015, which are incorporated herein by reference in their entireties.

FIELD OF THE DISCLOSURE

The present disclosure relates to one or more blister package assemblies and/or one or more systems and methods for producing the one or more blister package assemblies. The assemblies and systems and methods are utilized to package and/or protect one or more products and/or to display one or more products using a new and different blister card construction format.

BACKGROUND OF THE DISCLOSURE

Blister card systems are generally used to display, organize and dispense products stored therein. The blister card systems traditionally are hung or suspended from hooks and/or pegs are easily removed from the hooks and/or pegs by consumers for examination and/or purchase of the products by the consumers. The hooks and/or pegs, attached to display shelves, often suspend the products from one or more cut-outs formed within packaging of the blister card systems. Known blister card systems have pre-formed plastic packaging which includes at least one pre-formed plastic cavity sized or configured to receive and store one or more products, coated cards are required to seal either the blister to the card or the card to the card with the blister held in between the two cards. Both methods require a special machine that applies heat and/or pressure over time in a special cavity, to complete the sealing process. Often the preformed plastic cavity is made from thermoformed plastic and the backing is made from a paper-based material, for example, cardboard or paperboard, metal foil or one of many available plastics or a combination of any of these varied materials.

The size and shape of the preformed plastic cavity is based on the size and shape of the products being stored and enclosed within the preformed plastic cavity of the blister card system. Because different products, more often than not, have different sizes and/or shapes, the sizes and shapes of the preformed plastic cavities must also have different corresponding sizes and/or shapes. As a result, this requires special blister mould tooling to be manufactured to produce correctly sized blisters that properly hold the product to the card. Also required, as well, are a complete and separate set of additional specialized blister machine sealing tooling, which are required for each product, to seal the blister loaded with product to the card or card to card with the blister in between, for final assembly. Specialized machines must be used to seal the blister with the product inside to the card or for card to card sealing with the blister in between the cards. Currently all blister cards are produced this way. Each and every product to be placed onto a blister card requires both a preformed plastic cavity, mould tooling for same that has been designed and manufactured for each and every different product size and/or shape to be carded, plus the additional and expensive sealing equipment tooling required to attach the blister to the speciality coated card, which requires very specialized machines which are necessary to seal each preformed plastic cavity which has a different size and/or shape in order to adhere to the specially coated blister card using time, heat and pressure. Moreover, producing and sealing different preformed plastic cavities having different sizes and/or shapes requires manufactures or producers to purchase, utilize, maintain and repair multiple tooling and/or sealing equipment and machines. As a result, the purchasing, utilizing, maintaining and repairing of the multiple tooling and/or sealing equipment or machines required to produce and seal different sized and/or shaped preformed plastic cavities makes manufacturing different blister card systems for different products costly, untimely and often very labour intensive.

Moreover, traditional blister card systems, such as, for example, rotary or inline systems, require the above-mentioned standard blister machine tooling, such as, for example, blister framing tooling that has to be made exactly to fit and hold each blister, card and product and then feed each blister, card and product into the necessary sealing heated head section, which requires a custom heat sealing head to come down, heat seal the card, product and blister together which must exactly match all blisters and products needed to be sealed. This standard blister sealing process squeezes and heats the card together for completing its sealing process, which causes visible card crushing, marks and indentations in the final product which is one disadvantage of these standard blister sealing processes.

The assemblies and methods set forth in the present disclosure will produce and seal multiple and unlimited blister package designs styles for almost any different blister package assemblies required by any manufacturer, for storing and enclosing almost any different product(s) having different sizes and/or shapes, with or without, the use of pre-formed plastic cavities. When using film or a plastic cavity with this new process, large savings are achieved by eliminating or reducing the required multiple tooling needed and the complete elimination of any currently used sealing equipment machines and their very high operating costs. Moreover, the present assemblies and methods will reduce total packaging costs, production times and labour requirements associated with producing and sealing the different blister package assemblies by utilizing one or more of the following structural features and/or elements: a sheet or card having one or more scorings, foldings or petitioning to provide at least two, three, four, nine or more foldable portions; at least one cut-out window formed in the sheet; one or more compliant or stretchable films connected to a back side of the sheet and covering the at least one cut-out window(s) for enclosing at least one product between the one or more compliant films and at least one folded portion of the sheet; a conveyor belt system which may be continuously moving; two or more supports associated with the conveyor belt system for supporting at least one portion of the sheet during the production of the assembly; one or more moveable elements associated with the conveyor belt system for folding portions of the sheet onto each other to produce the folded assembly; a vacuum holding device associated with the conveyor belt system for applying a vacuum holding force to sheet or card positioned on the conveyor belt system; and an adjustable pocket or cavity, adjustable in both width and depth, built into the conveyor belt system. A plurality of adjustable product blister depths can be achieved for almost any product by angle adjustments made to the moveable elements position with respect to the position of the card. The adjustable product blister depths adjust in any and all axis's and planes required for the correct film pocket size. The moveable elements will allow for infinite blister depth adjustment, without tools, for making any required blister depth that may be needed for each and every product a manufacturer or customer wishes to have blister packaged a certain way and with a special look. As the foldable portions are being folded, tension in the stretchable film is relaxed which results in an increased width and/or depth of film pocket size for receiving the product.

The present systems and methods, for producing the present blister package assemblies, operate completely without any of the above-mentioned standard blister machine tooling. Instead, the present systems and methods utilize a machine assembly comprising movable convey belts that are slidable over the moveable box supports which operate a support bases for the movable convey belts. Said movable conveyor belts and box support are movable from side to side to provide one or more adjustable cavities that adjustable sizes, shapes, depths and/or configurations for receiving cards, blisters and/or products having different sizes, shapes, depths and/or configurations. As a result, the present systems and methods may quickly accommodate almost any size, shape and depth card, blister and/or possible and may fit almost any sized product sealable within the present blister package assemblies.

The present systems and methods does not utilize the heated head; thus no crushing, marks or indentations occur with respect to the final blister package assemblies produced by the present systems and methods. Instead, the present systems and methods utilize folding and sealing with one or more selected from adhesive, cohesive, pressure and a heat tunnel to seal the present blister package assemblies. As a result, the newest graphic print and design features which are not available to any other current blister system due to their sealing process (i.e., holding, squeezing and heating of the cards to complete and seal their package) may be utilized and/or incorporated into the present blister package assemblies and present systems and methods for producing said blister package assemblies.

SUMMARY OF THE DISCLOSURE

In embodiments, systems and methods may package retail products, provide a sheet divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet, load a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the window formed in the sheet, and fold the second part onto the first part to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.

In an embodiment, the systems and methods may have a blister product assembly production rate from about 100 assemblies/minute to about 450 assemblies/minute.

In an embodiment, the sheet may be made of paper-based materials, plastic or polymer-based materials or a combination thereof.

In an embodiment, the pre-formed blister may be made of a rigid or semi-rigid plastic.

In an embodiment, the pre-formed blister may be made of at least one polymer material.

In an embodiment, the systems and methods may further comprise coating an adhesive onto one or more sides of a flange of the pre-formed blister before the pre-formed blister is loaded into the window formed in the sheet.

In an embodiment, the systems and methods may further comprise adhering the first and second parts of the sheet together, via the adhesive coated onto one or more sides of the flange of the pre-formed blister, when, or after, the second part is folded onto the first part of the sheet.

In an embodiment, the systems and methods may further comprise adhering the first and second parts of the sheet together via cohesion or an adhesive when, or after, the second part is folded onto the first part of the sheet to produce the blister product assembly.

In an embodiment, the systems and methods may further comprise dispensing the sheet onto a conveyor belt prior to loading the pre-formed blister into the window formed in the sheet.

In an embodiment, the systems and methods may further comprise placing the pre-formed blister, by hand or by machine, into the window formed in the sheet for loading the pre-formed blister into the window.

In an embodiment, the second part of the sheet may have a window formed therein for receiving at least a portion of the pre-formed blister and/or a portion of the at least one retail product.

In embodiments, the systems and methods may package retail products, position a sheet on a conveyor belt system comprising an adjustable cavity, wherein the sheet is divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet, wherein the window formed in the sheet is positioned above the adjustable cavity of the conveyor belt system when the sheet is positioned on the conveyor belt system, load a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the window formed in the sheet and into the adjustable cavity of the conveyor belt system, and fold the second part onto the first part to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.

In an embodiment, the systems and methods may further comprise adjusting a width and/or depth of the adjustable cavity of the conveyor belt system to correspond to or to be similar to dimensions of the at least one retail product and/or the pre-formed blister prior to loading the at least one retail product and/or the pre-formed blister into the window formed in the sheet.

In an embodiment, the systems and methods may further comprise providing downward vacuum holding forces onto the sheet by a vacuum producing device of the conveyor belt system after the sheet is positioned on the conveyor belt system and/or providing downward vacuum holding forces onto the at least one retail product by the vacuum producing device after the at least one retail product is loaded into the window formed in the sheet.

In an embodiment, the method may have a blister product assembly production rate from about 100 assemblies/minute to about 450 assemblies/minute.

In an embodiment, the systems and methods may further comprise coating an adhesive onto one or more sides of a flange of the pre-formed blister before the pre-formed blister is loaded into the window formed in the sheet.

In an embodiment, the systems and methods may further comprise adhering the first and second parts of the sheet together, via the adhesive coated onto one or more sides of the flange of the pre-formed blister, when, or after, the second part is folded onto the first part of the sheet.

In an embodiment, the systems and methods may further comprise adhering the first and second parts of the sheet together via cohesion or an adhesive when, or after, the second part is folded onto the first part of the sheet to produce the blister product assembly.

In an embodiment, the systems and methods may further comprise placing the pre-formed blister, by hand or by machine, into the window formed in the sheet for loading the pre-formed blister into the window.

In an embodiment, the second part of the sheet may have a window formed therein for receiving at least a portion of the pre-formed blister and/or a portion of the at least one retail product.

BRIEF DESCRIPTION OF THE DRAWING

So that the features and advantages of the present disclosure can be understood in detail a more particular description of the systems and methods may be had by reference to the embodiments thereof that are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only some typical embodiments of the present systems and methods and are therefore not to be considered limiting of its scope, for the systems and methods may admit to other equally effective embodiments.

FIG. 1 illustrates a front plan view of a blister package assembly with a product enclosed therein in an embodiment.

FIG. 2 illustrates a front plan view of a blister package assembly with more than one product enclosed therein in an embodiment.

FIG. 3 illustrates a front plan view of a top side of a sheet of card stock paper petitioned into at least three portions and having at least one window formed therein and at least one compliant or stretchable film covering the at least one window in an embodiment.

FIG. 4 illustrates a front plan view of a bottom side of a sheet of card stock paper petitioned into at least one, two or three portions and having at least one window formed therein and at least one compliant or stretchable film connected to the portions of the sheet and covering the at least one window in an embodiment.

FIG. 5 illustrates a top plane view of a portion of the sheet shown in FIG. 4 showing one of the moveable elements in correct position to produce a properly sized product blister film pocket, just prior to being folded onto another portion of the sheet in an embodiment.

FIG. 6 illustrates a top plane view of the sheet shown in FIG. 5 after the portion of the sheet has been folded onto another portion of the sheet in an embodiment locking in the product depth for the blister pocket.

FIG. 7 illustrates a top plan view of the sheet shown in FIG. 6 after two portions of the sheet have been folded and sealed together onto the remaining portion of the sheet. Locking the product in place with multiple holding systems. A fugitive adhesive or other holding method such as, but not limited to, other adhesive types, cohesive, double sided tape etc., as a method to securely hold the product from behind, to the front side A3 of a portion of the sheet. The film blister pocket will lock the product into place from behind the front side A1 of an additional portion of the sheet with the film pocket adhered to the back side B1 of that additional portion, to produce the blister package assembly in an embodiment.

FIG. 8 illustrates a partial cross-sectional view of a blister package assembly having a product (i) connected to a portion of a folded sheet, (ii) extending through the window formed in the sheet, and (iii) enclosed between the at least one compliant, stretchable and heat shrinkable film and the portion of the sheet in which the product is connected to in an embodiment.

FIG. 9 illustrates a partial cross-sectional view of a blister package assembly provided on a conveyor or moving belt that has an adjustable cavity and vacuum holding device applying vacuum holding force to an adjacent portion of the card and the product position in the window in an embodiment.

FIG. 10 illustrates a front plan view of a bottom side of a sheet petitioned into three portions, having at least one window formed therein, and at least one compliant or stretchable film connected to the portions of the sheet and covering the at least one window having a product positioned therein in an embodiment.

FIG. 11 illustrates a front plan view of the bottom side of the sheet shown in FIG. 9 with one portion folded onto another portion and a portion of the product in an embodiment.

FIG. 12 illustrates a front plan view of the bottom side of the sheet shown in FIGS. 10 and 11 with a second portion folded onto the other portions to form the folded assembly in an embodiment.

FIG. 13. illustrates a front plan view of a bottom side of a sheet petitioned into a plurality of foldable portions, having at least one window formed in a first portion of the sheet, and at least one stretchable film connected to the plurality of foldable portions of the sheet in an embodiment.

FIG. 14 illustrates a front plan view of the bottom side of the sheet shown in FIG. 13 with upper and lower foldable portions folded onto the first portion of the sheet and the product in an embodiment.

FIG. 15 illustrates a front plan view of the bottom side of the sheet shown in FIGS. 13 and 14 with left and right foldable portions folded onto the first portion of the sheet to form the folded assembly in an embodiment.

FIG. 16 illustrates a front plan view of the front side of the folded assembly produced by folding the plurality of foldable portions onto the first portion of the sheet as shown in FIGS. 13-15 in an embodiment.

FIG. 17 illustrates a front plan view of a product connected to a carrier in an embodiment.

FIG. 18 illustrates a top plan view of a front side of a folded assembly displaying the product connected to the carrier as shown in FIG. 17 in an embodiment.

FIG. 19 illustrates a front plan view of a sheet of card stock paper petitioned into three portions and having two windows formed therein and a product connected to a carrier and sealed in a bag of film in an embodiment.

FIG. 20 illustrates the front plan view shown in FIG. 19, wherein a portion of the sheet has been folded onto the middle portion forming a pocket between the portions for receiving the product and carrier sealed in the bag of film in an embodiment.

FIG. 21 illustrates the front plan view shown in FIG. 20, wherein the product and carrier sealed in the bag of film is inserted into the pocket formed between the portions in an embodiment.

FIG. 22 illustrates the front plan view shown in FIG. 21, wherein the entire lengths of the product and carrier are inserted into the pocket formed between the portions in an embodiment.

FIG. 23 illustrates the front plan view shown in FIG. 22 after the third portion has been folded onto the other two portions enclosing at least portions of the carrier between the portions of the sheet in embodiment.

FIG. 24 illustrates a front plan view of a sheet of card stock paper petitioned into three portions and having two windows formed therein and a product connected to a carrier and sealed in a bag of film in an embodiment.

FIG. 25 illustrates the front plan view shown in FIG. 24, wherein the product and carrier sealed in the bag of film has been positioned on the middle portion of the sheet in an embodiment.

FIG. 26 illustrates the front plan view shown in FIG. 25, wherein a first outer portion of the sheet has been folded onto the middle portion such that the product extends outwardly from the window of the folded outer portion in an embodiment.

FIG. 27 illustrates the front plan view shown in FIG. 26, wherein a second outer portion of the sheet has been folding onto the middle and first outer portions such that the product extends outwardly from the windows formed in the first and second outer portions in an embodiment.

FIG. 28 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into two portions and having a window formed in one portion in an embodiment.

FIG. 29 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into three portions and having a window formed in the middle portion in an embodiment.

FIG. 30 illustrates a front plan view of a product connected to a carrier and/or sealed in a bag of film in an embodiment.

FIG. 31 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into at least two portions and having a window formed in one portion in an embodiment.

FIG. 32 illustrates a front plan view of a product a pre-formed blister sized to receive the product whereby an adhesive layer is provided on the pre-formed blister in an embodiment.

FIG. 33 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into at least two portions and having a product and pre-formed blister loaded into a window formed in one portion and sealed closed using adhesive or cohesive on the pre-formed blister or card in an embodiment.

FIG. 34 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into two portions and having a window formed in one portion that is covered with at least one stretchable film in an embodiment.

FIG. 35 illustrates a top plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.

FIG. 36 illustrates a first side plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.

FIG. 37 illustrates a second side plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.

FIG. 38 illustrates a first end plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.

FIG. 39 illustrates a second end plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.

FIG. 40 illustrates a perspective view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.

FIG. 41 illustrates a partial perspective plan view of a blister pack machine system having movable box supports slidable on horizontal crossbars in an embodiment.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure sets forth blister package assemblies and/or methods of producing blister package assemblies for packaging, securing, storing, enclosing, protecting, displaying and/or offering-for-sale one or more products. The assemblies and methods may package one or more products, enclosed between at least one compliant or stretchable film at least one portion of a sheet of card stock paper or other selected material, such that the one or more products extend through at least one window formed in the sheet. In embodiments, one or more windows may be formed in the sheet whereby each window is sized and shaped to display one or more products, which may be the same products, different products or a combination thereof. In embodiments, portions of the sheet may be folded over each other to produce the folded blister package assemblies such that the product may extend through a window formed in a portion of the sheet and be enclosed between the compliant or stretchable film and one or more folded portions of the sheet. It should be understood that the following terms may be used interchangeably throughout the present disclosure: sized; shaped; adapted; and configured.

Referring now to the drawings wherein like numerals refer to like parts, the present systems and methods may provide at least one folded blister package assembly 2 (hereinafter “assembly 2”) as shown in FIG. 1, configured to package at least one product 4. In embodiments, a folded blister package assembly 100 (hereinafter “assembly 100”) may be sized, shaped and/or configured to package, for example, a plurality of products 4 (hereinafter “products 4”) as shown in FIG. 2. Moreover, it should be understood that the present disclosure is not limited to a specific embodiment of the number of products 4 which may be packaged within the assembly 2 and/or the assembly 100 (hereinafter collectively referred to as “assemblies 2, 100”). For example, the assembly 100 may package three products 4 as shown in FIG. 2; however, it should be understood that the assembly 100 may be shaped, sized and/or configured to package, store and/or display any number of products 4 as known to one of ordinary skill in the art.

The products 4 may be, for example, cosmetic products, consumer products, food products, hard goods, durable goods, soft goods, pharmaceuticals, replacement parts, aerosols, consumables, consumer-grade goods, professional-grade goods and/or the like. In embodiments, the products 4 may be at least one or more products. The products 4 may be, for example, cosmetics, analgesics, medications, pharmaceuticals, razors, razor blades, camera film, batteries, videos, DVDs, smoking cessation products, infant formula, lip sticks, nail polishes, toothbrushes, vitamins, personal care products, home care products, toothbrushes, foodstuffs, packaged foods, kitchen supplies, bags, boxes, containers and/or the like. In embodiments, the products 4, which may be secured, stored, displayed and/or dispensed via the assemblies 2, 100, may be the same products, similar products, different products or a combination of same and different products. In embodiments, the products 4 may have same, similar and/or different sizes, shapes and/or configurations. The products 4 that may be any product(s) known to one of ordinary skill in the art that are configured, adapted, shaped and/or sized to be packed or stored within the assemblies 2, 100.

The assemblies 2, 100 and/or the products 4 may be accessible by a consumer through a front-side of a divider or shelf system (not shown in the drawings). In embodiments, the assemblies 2, 100 may have a cut-out opening 40 (shown in FIGS. 13-16) which may enable the assemblies 2, 100 to be suspended from a hook or a peg (not shown in the drawings) associated with the divider or shelf system. A consumer may remove and/or separate the assemblies 2, 100 from divider or shelf system and/or from the hook or peg to examine the products 4 packaged, secured, stored, enclosed, protected and/or displayed within the assemblies 2, 100. If desirable, the consumer may purchase or offer-to-buy the assemblies 2, 100 and/or the products 4. After which, the products 4 may be separated and/or removed from the assemblies 2, 100 by the consumer and the assemblies 2, 100 may be discarded and/or recycled by the consumer. Easy open features like, but not limited to, rear perforated pull tabs or tear tapes etc. to assist package opening can be added upon request or as desired.

FIGS. 1 and 2 show the folded assemblies 2, 100, respectively, which comprise at least one sheet 5 (hereinafter “sheet 5”) made of materials, such as, for example, paper-based materials, plastic or polymer-based materials or a combination thereof. In embodiments, the sheet 5 may be made of any materials that are capable, physically, of being folded onto and/or over itself to produce, form and/or assemble the folded assemblies 2, 100. For example, the sheet 5 may be made of one or more materials selected from the group consisting of paper corrugated or wood based materials, blister boards, coated styrene butadiene styrene, corrugated fibreboard, E-Flute corrugated fibreboard, stone paper, ceramic sheets, wood, melamine, standardized layers or sheets or combinations thereof. It should be understood that the present disclosure is not limited to a specific embodiment of the materials that may be used to make the sheet 5.

In embodiments, the sheet 5 may consist of a single layer of material. In other embodiments, the sheet 5 may consisting of more than one layer of material which may be connect, attached, adhered or laminated together to form the sheet 5. It should be understood that the present disclosure in not limited to specific embodiment of the number of layers of material that may be utilized to form sheet 5.

The sheet 5 may be divided or partitioned into two, three, four, nine or more portions by a dividing or partitioning process or method. In embodiments, the three or more portions of the sheet 5 may be formed or produced by a scoring process, such as, for example, a side cut scoring process or the like. As a result, one or more scores or folds may be positioned, provided and/or located between each of the three or more portions. When two or more scores or folds are present between each of the three or more portions, additional height dimension may be added to the folded assembly 2. As a result, gussets and/or other pull-out features may be provided or positioned in the additional height dimension that may be provided by the two or more scores or folds between each of the three or more portions of the sheet 5.

In embodiments, the sheet 5 may be divided or partitioned into a first portion 6, a second portion 8 and a third portion 10 (hereinafter collectively referred to as “portions 6, 8, 10”) as shown in FIGS. 3-5. Each of the portions of the sheet 5 has a front side and a back side located opposite with respect to the front side of each portion. For example, the first portion 6 has a front side A1 and a back side B1, the second portion 8 has a front side A2 and a back side B2, and the third portion 10 has a front side A3 and a back side B3 as shown in FIGS. 3 and 4. The sheet 5, the first portion 6, the second portion 8 and/or the third portion 10 may be produced, cut, scored and/or formed by one or more die-cut and/or scoring tools or equipment. The present disclosure should not be deemed as limited to a specific embodiment of a size and/or a shape of an outer perimeter of the sheet 5, the first portion 6, the second portion 8 and/or the third portion 10.

In embodiments, indicia 12 (hereinafter “indicia 12”) may be printed onto, displayed on and/or applied to one or more surfaces of the assemblies 2, 100. The indicia 12 may be printed onto or applied onto the one or more surfaces of the assemblies 2, 100 by one or more known printing and/or application techniques. The indicia 12 may comprise at least one of graphics, letters, numbers, symbols, photographs, holographics, pictures, scratch-n-sniff features, trademarks, designs, images, characters and/or the like. The indicia 12 may be associated with and/or indicative of the products 4 packaged, stored and/or enclosed within the assemblies 2, 100. Further, the indicia 12 may be associated with and/or indicative of a supplier of the products 4, a manufacturer of the products 4, a distributor of the products 4 and/or a third party associated with the products 4.

In embodiments, the indicia 12 may be in the form of, but not limited to, printed indicia that is printed or electronically transferred onto the one or more surface of the assemblies 2, 100. In other embodiments, the indicia 12 may be in the form of an adhesive label or attachment which may be applied or adhered to the one or more surface of the assemblies 2, 100. The indicia 12 may be any indicia that may be displayed on one or more surface of the assemblies 2, 100 as known to one of ordinary skill in the art.

In an embodiment, the indicia 12 may be printed onto or displayed on the front side A1 of the first portion 6 and the front side A2 of the second portion 8 as shown in FIGS. 1-4 and 7. As a result, the indicia 12 is displayed on front and rear sides of the assemblies 2, 100 after the assemblies 2, 100 are produced by folding the portions 6, 8, 10 onto each other and/or by adhering at least two portions of the portions 6, 8, 10 to each other as shown in FIGS. 1, 2 and 7. For example, the indicia 12 displayed on the front side A1 of the first portion 6 may be displayed on the front side of the assemblies 2, 100 after the assemblies 2, 100 have been produced, formed and/or assembled. Further, the indicia 12 displayed on the front side A2 of the second portion 8 may be displayed on the rear side of the assemblies 2, 100 after the assemblies 2, 100 have be produced, formed and/or assembled.

The folded assemblies 2, 100 may be produced, formed and/or assembled by at least one automation process or by human labour. For example, the portions 6, 8, 10 of the sheet 5 may be folded and/or adhered to produce, form and/or assembly the folded assemblies 2, 100 by human hands or by at least one mechanical apparatus. In embodiments, the at least one mechanical apparatus may comprise a continuous moving conveyor belt (see FIGS. 9, 35 and 39-41) that transports the sheet 4 from one place to another while the portions 6, 8, 10 are being folded over or onto each other and/or are being adhered to each other to produce, form and/or assemble the folded assemblies 2, 100. In embodiment, the at least one mechanical apparatus may be, but not limited to, a conveyor belt system 30 (shown in FIG. 9) having stationary and movable parts which may utilized to fold and/or adhere the portions 6, 8, 10 to each other to produce, form and/or assemble the folded assemblies 2, 100.

The sheet 5 has at least one window 14 (hereinafter “the window 14”) formed therein for displaying, housing, securing and/or storing the products 4 after the portions 6, 8, 10 are folded onto each other and/or adhered to each other to form the assemblies 2, 100. For example, the sheet 5 may have one window 14 for displaying, housing, securing and/or storing the product 4 as shown in FIGS. 1, 3-6 and 8 or the sheet 5 may have a plurality of windows 14 for displaying housing, securing and/or storing more than one product 4 as shown in FIG. 2. In embodiments, the window 4 is formed in one of the portions 6, 8, 10 of the sheet 5. For example, the window 4 may be formed in the first portion 6 as shown in FIGS. 1-6 and 8-11 and may extend through the sheet 5 from the front side A1 of the first portion 6 to the back side B1 of the first portion 6.

The window 14 is configured to receive, house and/or store at least a portion of the products 4 after the folded assemblies 2, 100 are produced, formed and/or assembled by folding the portions 6, 8, 10 onto each other and/or adhering the portions 6, 8, 10 together. In embodiments, the window 14 formed in the sheet 5 may be configured to receive two or more products 4 (not shown in the drawings). The windows 14 may be, for example, but not limited to, cut-out windows formed in the sheet by cut-out or punch-out techniques as known to one of ordinary skill in the art.

In embodiments, the window 14 may be configured to receive, house and/or store at least a portion of the product 4 and may have a perimeter that may be smaller than, the same as, substantially the same as, substantially similar to, or greater than the perimeters of the product 4. The perimeters of the window 14 may comprise a geometrical shape selected from a circular shape, an oval shape, a square shape, a rectangular shape, a triangular shape, a polygonal shape and combinations thereof. In an embodiment, the perimeters of the window 14 may be smaller than, the same as, substantially similar to or corresponding to the perimeters of the products 4. In embodiments, the perimeters of the windows 14 may be differently shaped perimeters as shown in FIG. 2. In embodiments, the products 4 may firmly fit or be positioned within the window 14 or within the perimeters of the window 14 after the portions 6, 8, 10 are folded onto each other and/or joined together.

The product 4 may be adhered, bonded or glued, connected, attached and/or secured to the front side A3 of the third portion 10 of the sheet 5 before the assemblies 2, 100 are produced, formed and/or assembled by folding the portions 6, 8, 10 onto each other and/or joining the portions 6, 8, 10. In an embodiment, at least one first adhesive layer 16 (hereinafter “the first adhesive layer 16”) may adhere a back side of the product 4 to the front side A3 of the third portion 10 of the sheet 5 as shown in FIG. 8. As a result, the product 4 may be connected, attached, secured and/or adhered to the third portion 10 of the sheet 5 via first adhesive layer 16. During production of the assemblies 2, 100, the first adhesive layer 16 may be applied to the back side of the product 4 or to the front side A3 of the third portion before the product 4 and the third portion 10 are adhered or joined together.

In embodiments, the first adhesive layer 16 may be, but not limited to, a fugitive adhesive or glue, a credit card glue, a E-z-release glue, a hotmelt adhesive, a pressure-sensitive adhesive, a cold glue, a cohesive, a double sided tape, a single sided tape with an adhesive on its back side, an animal glue or combinations thereof. After the assemblies 2, 100 are purchased by a consumer, the consumer may open the assemblies 2, 100 and remove the product 4 displayed therein. When removing the product 4 from the first adhesive layer 16, no residue of the first adhesive layer 16 is present on the back side of the product 4. As a result, no damage will be caused to the product 4 by the first adhesive layer 16 and/or by the removal of the product 4 from the assemblies 2, 100. Easy open features such as, but not limited to, perforated pull tabs, tear tapes and separator strips can be added to assist final package opening to remove the product 4 from the assemblies 2, 100.

As shown in FIGS. 1-6 and 8, at least a portion of the window 14 or the window in its entirety is covered by at least one compliant film 18 (hereinafter “film 18”) which is connected, attached or adhered to the back side of the sheet 5. For example, the film 18 may be connected, attached and/or adhered to the back side B1 of the first portion 6, the back side B2 of the second portion 8 and/or the back side B3 of the third portion 10 as shown in FIG. 4. The film 18 may be, but is not limited to, a stretchable, heat shrinkable film which may, in an embodiment, be a clear compliant plastic film layer, such as, but not limited to, a polyolefin film layer that may be adhered to the bottom side of the sheet 5. The film 18 may comprise a single film layer or more than one film layer. The film 18 may be at least a single sheet film having an outer perimeter which may be configured to cover the at least one window 14, at least a portion of the back side of the sheet 5, at least a majority of the back side of the sheet 5 or all of the back side of the sheet 5. The outer perimeter the film 18, in an unstretched state or manner, may be large enough that the film 18 may cover more than the window 14 and/or may allow the film 18 to be connected, attached and/or adhered to one or more portions of the back side B1 of the first portion 6, the back side B2 of the second portion 8 and/or the backs side B3 of the third portion 10. In the unstretched state or manner, the film 18 may extend across the window 14 in a firmly tensioned or a relaxed state or manner.

In embodiments, the film 18 may be made from, but is not limited to, at least one clear compliant film or heat activated clear film. Heat active films become loose or relaxed and extremely pliant when activated by heat, and then subsequently harden when cooled. For example, the at least one heat activated film may be, for example, a skin film as known to one of ordinary skill in the art. In embodiments, the film 18 may be any film layer type that is capable of being laminated and/or attached to the back side of the sheet 5, which may provide a plurality of characteristics that may be derived from different materials used in each layer of a multiple layered film 18, as well as a total number of film layers that may be combined to produce the multiple layered film 18.

In embodiments, the film 18 may be made of, but not limited to, a flexible rubber or rubber-like material or a polymeric packaging material that may or may not have one or more holes or pores formed therein. The film 18 may comprise one or more film layers which may or may not be made of the same material. In embodiments, the film 18 may be a composite film made of two or more different materials. In embodiments, the film 18 may be crosslinked or crosslinkable. In an embodiment, the film 18 may be produced by monoaxial or biaxial stretching prior to connecting, attaching and/or adhering the film 18 to the sheet 5. As a result, the film 18 may have an orientation, such, as, for example, a uniaxial or biaxial orientation The film 18 may have, but not limited to, a film thickness in a range of about 15 to about 250 microns, about 10 to about 25 microns, about 15 to about 30 microns or may be about 16.4545 microns. In embodiments, the film 18 may exhibit one or more of the following characteristics:

(i) a haze (ASTM Test Method D1003-95) in a range of about 2.5 to about 70%, or about 3, 5.5 or 8%;

(ii) a gloss (ASTM Test Method D2457-90) in a range of about 90 to about 115% or about 107%;

(iii) a density (ASTM Test Method D-1505) in a range of about 0.95 to about 1.20 g/cm³ or about 1.08 g/cm3;

(iv) a coefficient of friction (ASTM Test Method D-1894-95) in a range of about 0.1 to about 0.55 f/ss, kinetic, or about 0.20 or 0.25 f/ss, kinetic;

(v) a tensile strength in the machine direction (ASTM Test Method D882) in a range of about 1.25 to about 60×1000 psi, about 6 to about 6.5×1000 psi, about 4.9 to about 7×1000 psi, about 5.8 to about 6.1×1000 psi, about 8.5 to about 9.2×1000 psi, about 5 to about 10×1000 psi or about 2.5, 13, 16, 17, 18, 20, 48 or 52×1000 psi;

(vi) a tensile strength in the transverse direction (ASTM Test Method D882-95) in a range of about 4 to about 7×1000 psi, about 2.5 to about 4.6×1000 psi, about 7 to about 21×1000 psi or about 14, 16, 17, 18, 20 or 32×1000 psi;

(vii) an elongation at break in the machine direction (ASTM Test Method D882-95) in a range of about 100 to about 600%, about 400 to about 800%, about 550 to about 650%, about 250 to about 350% or about 150, 400 or 600%;

(viii) an elongation at break in the transverse direction (ASTM Test Method D882-95) in a range of about 10 to about 150%, about 500 to about 1000%, about 750 to about 950%, about 700 to about 800% or about 20, 100, 650 or 850%; and

a melting point in a range of about 65 to about 350° C.

One or more second adhesive layers 20 (hereinafter “second adhesive layers 20”) may be positioned on, provided on and/or applied to one or more portions of the top side and/or bottom side of the sheet 5. For example, the second adhesive layers 20 may be applied to or provided on one or more portions of the top side A1 of the first portion 6, the bottom side B1 of the first portion 6, the top side A2 of the second portion 8, the bottom side B2 of the second portion 8, the top side A3 of the third portion 10 and/or the bottom side B3 of third portion 10. Further, the second adhesive layers 20 is applied to or provided on the back side of the sheet 5 such that the film 18 is adhered to the back side of the sheet 5 via the second adhesive layers 20 prior to the production of the assemblies 2, 100. Moreover, the second adhesive layers 20 applied to or provided on the sheet 5 adheres or attaches the portions 6, 8, 10 together when the portions 6, 8, 10 are folded onto each other to produce, form and/or assembly the assemblies 2, 100.

In embodiments, the second adhesive layers 20 may comprise, but is not limited to, a pressure-sensitive adhesive, a crosslinkable adhesive, a heat-activatable adhesive, a hotmelt adhesive, a cohesive, a double sided tape, a single sided tape with an adhesive on its back side or combinations thereof. Adhesive strengths of the second adhesive layers 20 may be greater than an adhesive strength of the first adhesive layer 16. Moreover, the adhesive strength of the second adhesive layers 20 sufficiently bonds or adheres the portions 6, 8, 10 together to produce the assemblies 2, 100 such that tempering with and/or theft of the product 4 enclosed within the assemblies 2, 100 is prevented or significantly reduced. The second adhesive layers 20 may be applied to or positioned on the front and back sides of the sheet 5 by application techniques or processes as known to one of ordinary skill in the art.

As shown in FIGS. 3 and 4, the second adhesive layer 20 may be applied to or positioned on an outer edge, opposite to the edge adjacent to the second portion 8, of the top side A3 and bottom side B3 of the third portion 10. Further, the second adhesive layer 20 may be applied to an outer edge, opposite to the edge adjacent to the second portion 8, of the bottom side B1 of the first portion 6 as shown in FIG. 4. The second adhesive layer 20 of the first and third portions 6, 10 adheres the portions 6, 8, 10 together when the portions 6, 8, 10 are folded onto one another to produce, form and/or assembly the assemblies 2, 10.

When the portions 6, 8, 10 are folded onto each other to produce the assemblies 2, 10, the second adhesive layer 20 located on the bottom side B3 of the third portion 10 adheres the bottom side B3 of the third portion 10 to the bottom side B2 of the second portion 8. Further, the second adhesive layer 20 on the top side A3 of the third portion 10 adheres the top side A3 of the third portion 10 to the bottom side B1 of the first portion 6, and the second adhesive layer 20 on the bottom side B1 of the first portion 6 adheres the bottom side B1 of the first portion 6 to the top side A3 of the third portion 10. As a result, the third portion 10 and the film 18 are located or positioned between the bottom side B1 of the first portion 6 and the bottom portion B2 of the second portion 8 as shown in FIG. 8. Moreover, the top side A1 of the first portion 6, displaying indicia 12, and the top side A2 of the second portion 8, displaying indicia 12, are exposed or facing outward such that the indicia 12 is displayed to or viewable by a consumer viewing the assemblies 2, 100 as shown in FIGS. 1, 2 and 7.

In FIG. 8, the product 4 was positioned in the window 14 formed in the first portion 6 prior to the folding of the portions 6, 8, 10 onto each other. As the portions 6, 8, 10 are folded onto each other, the first adhesive layer 16 adheres the product 4 to the top side A3 of the third portion 10, and the product 4 pushes against and/or stretches the film 18 covering the window 14 and extends outwardly away from the top side A1 of the first portion 6. As a result, the film 18 is stretched outwardly by the product 4 and the product 4 is enclosed, housed, stored and/or secured between the film 18 and the second portion 8, the third portion 10 and/or the first adhesive layer 16.

In an embodiment, the first adhesive layer 16 may be excluded from the assemblies 2, 100 and the film 18 may apply a force to the product 4 in the direction towards the top side A3 of the third portion 10. As a result, the product 4 may be held or maintained in position within the window 14 between film 18, the second portion 8 and/or the third portion 10.

Subsequently the consumer may, if desired, examine and/or view the product 4 which extends outwardly from the window 14 formed in the first portion 6 of the sheet 5 as shown in FIGS. 1 and 2. The window 14 allow the consumer or another third party to visually and/or physically examine the product 4 being displayed and/or packaged by the assemblies 2, 100. Moreover, after examining and/or viewing the product 4 via the window 14, a consumer may desire to purchase the product 4 being displayed and/or packaged by the assemblies 2, 100.

The first adhesive layer 16, the second adhesive layer 20, the sheet 5 and/or the film 18 may prevent or substantially prevent the product 4 from being separated or removed from the assemblies 2, 100. As a result, the first adhesive layer 16, the second adhesive layer 20, the sheet 5 and/or the film 18 may prevent or reduce theft of, damage to and/or destruction of the product 4 by firmly securing the product 4 within the assemblies 2, 100.

When the product 4 pushes against or stretches the film 18 outwardly away from the top side A1 of the first portion 6, the film 18 may be contoured to one or more outer surfaces of the product 4 and/or the product 4 may be completely enclosed between the film 18 and first adhesive layer, the second portion 8 and/or the third portion 10. By enclosing the product 4, the film 18, the portions 6, 8, 10 and/or the first adhesive layer 16 may prevent or reduce theft of, damage to, destruction of, opening of, activating of, tampering with and contamination of the product 4. Additionally, enclosing the product 4 may reduce exposure to dust, dirt and/or surrounding environmental conditions and/or elements.

FIG. 1 shows the assembly 2 displaying the product 4 in the window 14 enclosed between the film 18 and the portions 6, 8, 10 of the sheet 5. FIG. 2 shows the assembly 100 displaying a plurality of products 4 in a plurality of windows 14 enclosed between the film 18 and the portions 6, 8, 10 of the sheet 5. FIG. 3 shows the front side of the sheet 5 comprising the top side A1 of the first portion 6, the top side A2 of the second portion 8, the top side A3 of the third portion 10, the window 14, and the film 18 covering the window 14. In embodiments, the second adhesive layer may be positioned on the outer edge of the top side A3 of the third portion 10 of the sheet 5 for connecting, attaching and/or adhering an additional structural feature to the assembly 2, such as, for example, a hologram, a product sample and/or a selling feature or the like.

FIG. 4 shows the back side of the sheet 5 comprising the back side B1 of the first portion 6, the back side B2 of the second portion 8, the back side B3 of the third portion 10, the window 14 covered by the film 18, the second adhesive layers 20 positioned on the outer edges of the bottom side B1 of the first portion 6 and the bottom side B3 of the third portion 10, and the film 18 connected or adhered to the bottom side of the sheet 5 via the second adhesive layers.

FIG. 5 shows the product 4 positioned in the window 14 and supported in the window 14 by the film 18 covering the window 14 and the bottom side B3 of the third portion 10 being folded onto the bottom side B2 of the second portion 8. The product 4 may be hand loaded into the window 14 of the sheet 5 or may be automatically loaded by a fed machine or apparatus. When the product 4 is loaded, the product pushes or stretches the film 18 covering the window outward with respect to the top side A1 of portion 6 of the sheet 5. As a result, a film pocket, having an initial depth and/or width, is formed which contains and/or housing the product. When the bottom side B3 of the third portion 10 is folded onto the bottom side B2 of the second portion 8, the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.

After the sheet 5 is dispensed and loaded with the product 4, the sheet 5 is conveyed into subsequent next machine section or station, where the sheet 5 will be automatically glued or adhered, folded and sealed to produce the folded assembly 2. Prior to producing the folded assembly, the first adhesive 16 and/or the second adhesive 20 may be applied to one or more portions of the portions 6, 8, 10 to facilitate securing the portions 6, 8, 10 to each other to produce the folded assembly 2. The folding may be accomplished by human hands; however, the conveyor belt system 30, which may be continuously moving, may be utilized to produce the folded assembly 2. In embodiment, at least to stationary machinery rails or elements 22 (hereinafter “stationary elements 22”) may be positioned under the first portion 6 and adjacent to the top side A1 of the first portion 6. As a result, the sheet 5 or the first portion 6 of the sheet 5 may be supported and/or maintained in a fixed position via the stationary elements 22. At least one movable machinery rail or element 24 (hereinafter “movable element 24”) may lift the third portion 10 upwards and/or towards the first portion 6 as shown in FIG. 5. As a result, the third portion 10 is folded onto the second portion 8 and the bottom side B3 of the third portion 10 is adjacent to or in direct contact with the bottom side B2 of the second portion 8. The second adhesive layer 20 on the bottom side B3 of the third portion 10 connects, attaches and/or adheres the bottom side B3 of the third portion 10 to the bottom side B2 of the second portion. As a result, the movable element 24 is adjacent to the top side A3 of the third portion 10 as shown in FIG. 6. The positioning angle of the movable element 24 may be adjusted to adjust the depth of the film pocket formed by the film 18 that houses the product 4. As a result, the adjusted positioning angle of the movable element 24 regulates, adjusts and/or controls the product film blister depth upwardly or downwardly as required or desired.

The stationary elements 22 and/or the movable element 24 (hereafter collectively referred to as “elements 22, 24”) may fed, handle and transport the sheet 5 through a package finishing process to produce, form and/or assemble the assemblies 2, 100. The sheet 5 may be automatically dispensed with film adhered thereto, and then the sheet 5 may be fed onto a specialized conveyor for loading the product 4 by hand or automatically.

FIG. 6 shows the second adhesive layers 20 positioned on the top side A3 of the third portion 10 and the bottom side B1 of the first portion 6 of the sheet 5 which is supported by the stationary elements 22. The movable element 24 is subsequently positioned under the second portion 8, located below the third portion 10 after the folding of the third portion 10 onto the second portion 8, and lifts the second and third portions 8, 10 upwards and/or towards the bottom side B1 of the first portion 6. As a result, the top side A3 of the third portion 10 is folded onto the bottom side B1 of the first portion 6 as shown in FIG. 7. When the top side A3 of the third portion 10 is folded onto the bottom side B1 of the first portion 6, the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.

Alternatively, the third portion 10 may be folded onto the first portion 6 by hand. The top side A3 of the third portion 10 and the bottom side B1 of the first portion 6 are connected, attached and/or adhered together via the second adhesive layers positioned on the top side A3 of the third portion 10 and/or the bottom side B1 of the first portion 6. As a result, the product 4 is enclosed, packed, encircled and/or stored between the film 18 and the second portion 8 and/or the third portion 10 as shown in FIG. 8.

In an embodiment, the film may be micro-perforated with micro-openings or micro-pores (not shown in the drawings) which may be invisible to the naked eye. The micro-openings or micro-pores may extend across a portion of the surface area of the film 18 or across the entire surface area of the film 18. The micro-openings or micro-pores allow air to escape or pass as the portions 6, 8, 10 are being folded onto each other to produce the assembly 2. Additionally, the micro-openings or micro-pores allow or facilitate improved adhesive penetration by the second adhesive layers and improved bond strength between the portions 6, 8, 10 of the sheet 5.

Prior to folding the third portion 10 onto the first portion 6, the first adhesive layer 16 may be applied and/or positioned directly onto the back side of the product 4 and/or onto an area of the top side A3 of the third portion 10. As the third portion 10 is folded onto the first portion 6, the top side A3 of the third portion 10 applies force to the back side of the product 4 which causes the product 4 to push against and/or stretch the film 18 outwardly away from the top side A1 of the first portion 6 as shown in FIG. 8. As a result, a pocket is formed by the film 18 that matches or substantially matches the outer perimeter of the product 4. The pockets depth adjustment is made by changing the angles of the elements with respect to the position of the sheet 5. The first adhesive layer 16 adheres the back side of the product 4 to the top side A3 of the third portion 10 to secure and protect the product 4 within the assembly 2. Moreover, the first adhesive layer 16 may prevent or substantially reduce movement of, turning of and/or any unwanted position changes of the product 4 after production of the assembly 2.

After the assembly 2 has been produced and the product 4 is enclosed and packaged within the assembly 2. The assembly 2 may be passed through a low temperature heat tunnel, which eliminates or substantially reduces any wrinkles or folds that may have formed in the film 18 caused by the product 4. As a result, the product 4 wrapped within the film 18 exhibits a surprising and unexpected sparkling finished appearance. Further, by passing the assembly 2 through the low temperature heat tunnel, the film 18 wraps tightly or closely around the product 4. The low temperature heat tunnel may be maintained at, but is not limited to, a temperature range from about 100° F. to about 350° F. The necessary temperature of the heat tunnel is directly related to production speed of the assembly 2. If the production speed is high, such as, for example, three-hundred assemblies per minute, then the temperature of the heat tunnel should be maintained at a range of about 200° F. to 300° F. The assembly 2 may completely pass through the heat tunnel in a time duration of greater than 0.1 second to no more than 5 seconds. In embodiments, the time duration may be from 0.25 to 3 seconds, 0.5 to 2.5 seconds or 1 to 2 seconds.

FIG. 9 shows a partial cross-sectional view of a folded assembly 2, which was produced by the method illustrated in FIG. 5-7, positioned on the conveyor belt system 30. In embodiments, an adjustable cavity 32 may be built or incorporated into the conveyor belt system 30 which may be adjustable to a width and/or depth that corresponds to the dimensions of the product 4 and/or dimensions of the film pocket formed by the film 18 housing the product 4. As a result, the placement and/or position of the product 4 in the film pocket may be controlled and/or adjusted by the adjustable cavity 32 of the conveyor belt system 30.

In embodiments, a vacuum producing device 34 may be built or incorporated into the conveyor belt system 30 such that the vacuum producing device 34 may apply or provide downward vacuum holding forces (illustrated by the downward arrows towards the vacuum producing device 34) to the sheet 5, the top side A1 of the first portion 6, the product 4 and/or the film 18. As a result of the downward vacuum holding forces, the sheet 5, the top side A1 of the first portion 6, the product 4 and/or the film 18 may be held or pulled tightly or firmly against a top side of the conveyor belt system 30 during the assembly process for producing and/or folding the folded assembly 2. The vacuum holding forces may be applied by the vacuum producing device 34 during one or more portions of the assembly process or during the entire assembly process for producing the folded assembly 2.

In embodiments, at least one section or portion of the sheet 5 may be held flat against the conveyor belt system 30 via the vacuum holding forces, and another section or portion of the sheet may be controlled or moved up or down by the at least one movable element 24. As a result, physical control of the depth film pocket may be achieved by the conveyor belt system 30. In embodiments, high speed control of the film pocket and product is essential to a successful machine outcome.

An added value added by inclusion of the vacuum holding force to the conveyor belt system 30, with adjustable cavity, may be exact sheet/card and film pocket is exact product position and control through the entire process. Another added advantage from adding vacuum holding forces to the conveyor belt system 30, is that a downward holding force may be exerted on both the film pocket and product 4, when the film 18 may be micro-perforated, which may allow the air and therefore the vacuum force to also pass through the film 18 and apply the same downward force onto the product 4 and not just to the film 18 into the adjustable cavity. This extra card/sheet control, film pocket and product holding force may a significant advantage over known conveyor belt system. As a result, it may be extremely significant and influential in achieving the highest line speeds possible, while still maintaining the correct product and film pocket control through the complete assembly process, to produce very high quality carded and acceptable finished goods.

FIGS. 10-12 show another method of folding the portions 6, 8, 10 to produce the folded assembly 2. The first portion 6 may be located or positioned between the second and third portions 8, 10, may have the window 14 formed therein, whereby the film 18 may be connected and/or covering the back sides of the portions 6, 8, 10 and the product 4 may be loaded into the window 14 and contacting the film 18 covering the window 14. The width of the third portion 10 may be less than the widths of the first and second portions 6, 8 as shown in FIGS. 10 and 11 or may be the same or substantially the same as the widths of the first and second portions 6, 8 as illustrated by the dashed lines shown in FIG. 10. The second adhesive layer 20 may be applied onto or provided at one or more portions of the back side B1 of the first portion 6, the back side B2 of the second portion 8 and/or the back side B3 of the third portion. The first adhesive layer may be applied onto the back side of the product 4 and/or provided at one or more portions of the back side B2 of the second portion and/or the back side B3 of the third portion 10.

As shown in FIG. 10, the conveyor belt system 30 may have at least two stationary elements 22, which may be positioned and/or located under the first portion 6, and/or at least two movable elements 24 whereby one movable element 24 is positioned or located under the second portion 8 and another movable element 24 is positioned or located under the third portion 10. As a result, the stationary elements 22 support the card 5 and the movable elements 24 rise or move to fold and/or adhere the back side B3 of the third portion 10 and the back side B2 of the second portion 8 onto the back side B1 of the first portion 6 to produce the folded assembly 2.

In embodiments, the movable element 24 positioned under the third portion 10 may move, rise and/or lift the third portion 10 such that the bottom side B3 of the third portion 10 is folded onto and/or adhered to the bottom side B1 of the first portion 6 as shown in FIG. 11. As a result, a portion of the product 4 may be enclosed and/or positioned between the bottom side B3 of the third portion 10 and the film 18 covering the window 14. In embodiments, one or more portions of the top side A3 of the third portion 10 may have the second adhesive layer 20 applied thereon for adhering the second and third portion 8, 10 together to produce the folded assembly 2. When the bottom side B3 of the third portion 10 is folded onto the bottom side B1 of the first portion 8, the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.

In embodiments, the movable element 24 positioned under the second portion 8 may move, rise and/or lift the second portion 8 such that the bottom side B2 of the second portion 8 is folded onto and/or adhered to the bottom side B1 of the first portion 6 and/or the top side A3 of the third portion 10 to produce the folded assembly 2 as shown in FIG. 12. As a result, the remaining and/or uncovered portion of the product 4 may be enclosed, sealed, secured and/or positioned between the bottom side B2 of the second portion 8 and the film 18 covering the window 14. In embodiments, the second adhesive layer 20 seals and/or adheres the portions 6, 8, 10 together to produce the folded assembly 2 and/or the first adhesive layer 16 secures and/or adheres the product to second and third portions 8, 10. When the bottom side B2 of the second portion 8 is folded onto the bottom side B1 of the first portion 6, the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.

In embodiments, the sheet 5 may be divided, separated, petitioned, cut, scored and/or folded into a plurality of foldable portions as shown in FIG. 13. The window 14 is formed in the first portion 6 of the sheet 5, the top and bottom edges of the first portion 6 are attached and/or connected to the third portion 10 which is foldable onto the back side B1 of the first portion 6, and the left and right edges of the first portion 6 are attached and/or connected to the second portion 8 which is foldable onto the back side B1 of the first portion 6. The film 18 may be attached or connected to or may cover one or more portions of the back sides of the portions 6, 8, 10. In an embodiment, the film 18 may be attached or connected to or may cover all back sides of the portions 6, 8, 10 as shown in FIG. 13.

The product 4 may be loaded into and/or positioned in the window 14 on the film 18 such that the film pocket extending outwardly way from the top side A1 of the first portion is formed by the film 18 and the product 4. The third portion 10 located at the top and bottom edges of the first portion 6 may be fold inward and/or onto the back side B1 of the first portion 6 as illustrated by the arrow extending from the bottom side B3 of the third portion 10 to the bottom side B1 of the first portion 6 as shown in FIG. 10. As a result, upper and lower portions of the second portion 8 may also fold inward and/or onto the back side B2 of the second portion as shown in FIG. 14.

The back side of the product 4 may be at least partially covered by the third portion 10 such that at least a portion of the product 4 in the film pocket is enclosed between the film 18 and the third portion 10. When the bottom side B3 of the third portion 10 is folded onto the bottom side B1 of the first portion 6 and/or the bottom sides B2 of the upper and lower portions of the second portion 8 are folded on the bottom side B2 of the second portion 8, the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.

The second portion 8 located on at the right and left edges of the first portion 6 may be folded inward and/or onto the back side B1 of the first portion 6 as illustrated by the arrows extending from the back side B2 of the second portion 8 to the bottom side B1 of the first portion 6. The second portion 8 located on the right and left edges of the first portion 6 may contact each other and/or may seal the product 4 within the folded assembly 2 as shown in FIG. 15. As a result, the folded assembly 2 is provided and the product 4 is sealed, secured and/or enclosed between the film 18 and the second and third portions 8, 10 of the sheet 5 as shown in FIGS. 15 and 16. When the bottom side B2 of the second portion 8 is folded onto the bottom side B1 of the first portion 6, the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.

First adhesive layers 20 may be provided or applied onto one or more portion of the back sides of the portions 6, 8, 10 of the sheet as shown in FIG. 13. When the second and third portions 8, 10 are folded onto the back side B1 of the first portion 6, the first adhesive layers 20 may adhere the portions 6, 8, 10 together to produce or form the folded assembly 2. In embodiments, the first adhesive layer 16 may be provided or applied to the product 4 and/or one or more portions of the back sides B2, B3 of the second and third portions 8, 10 as shown in FIG. 10. As a result, the second adhesive layer 16 may adhere the product 4 to at least a portion of the second and third portions 8, 10 when the second and third portions 8, 10 are folded onto the back side B1 of the first portion 6.

FIG. 17 shows the product 4 connected, attached and/or adhered to a carrier 42 prior to the product 4 and carrier 42 being loaded into the window 14 that is covered with the film 18. The first adhesive 16 layer may be applied to the product 4 and/or the carrier 42 prior to connecting the product 4 and the carrier 42 together. As a result, the first adhesive layer 16 may adhere the product 4 to the carrier 42 prior to placing the product 4 and carrier 42 in the window 14 of the first portion 6. The carrier 42 may be made of one or more materials selected from the group consisting of paper corrugated or wood based materials, blister boards, coated styrene butadiene styrene, corrugated fibreboard, E-Flute corrugated fibreboard, stone paper, ceramic sheets, wood, melamine, standardized layers or sheets or combinations thereof. It should be understood that the present disclosure is not limited to a specific embodiment of the materials that may be used to make the top card 10, the bottom card 20 and/or the carriers 30 of the system 2.

The perimeter of the carrier 42 may have the same or substantially the same shape, size, configuration and/or dimensions as the perimeter of the window 14 of the first portion 6. When the product 4 and carrier 42 are loaded and/or positioned within the window 14 prior to folding the second and third portions 8, 10 onto the back side B1 of the first portion 6, the perimeter or outer edges of the carrier 42 may contact, abut and/or be adjacent to the perimeter or outer edges of the window 14 as shown in FIG. 18. Frictional forces may be applied to or present at the perimeter or outer edges of the carrier and the perimeter or outer edges of the carrier 42. As a result of the frictional forces, the carrier 42 may be firmly connected, attached and/or secured to the perimeter of the window 14 such that the carrier 42 and the product 4 may not be separated or removed from the window 14 without application of an external force or pressure. Moreover, the product 4 is firmly connected, attached and/or secured within the window 14 via the carrier 42.

The assemblies 2, 100 and/or the sheet 5 may comprise a tamper evident system or element (not shown in the drawings). The tamper evident element may comprise, but is not be limited to, detectable nano-particles, watermarks, 3-D security images or elements, RFID tags, bar codes, 3-D security ribbons and color-changing elements or ink wells. The tamper evident element provides an anti-counterfeiting feature for the assemblies 2, 100.

Producing, forming and assembling the assemblies 2, 100 via the conveyor belt 30 having stationary elements 22, at least one movable element 24, and, optionally, a heat tunnel achieve fast, high speed production of the assemblies 2, 100. In an embodiment, production of the assemblies 2, 100 may be as high as four-hundred (400) assemblies per minute or greater.

FIG. 19 shows a back side of a sheet 5 petitioned, cut or scored into three portions 6, 8, 10 and having a window 14 formed in the first portion 6 and the third portion 10, and a product 4 connected, attached, adhered, banded and/or affixed to a carrier 42. The product 4 and carrier 42 are sealed in a bag made of a film material, such as, film 18. The window 14 may extend to or end at the one side of the perimeter of the third portion 10 of the sheet 5. The windows 14 may be sized, shaped and/or configured to receive and/or house the product 4 sealed in the bag of film 18. As a result, at least a portion of the product 4 may extend through the windows 14 after the first and third portions 6 and 10 have been folded onto the second portion 8.

One or more portions of the back sides B1, B2 and/or B3 of the first, second and third portions 6, 8, 10 may be coated with and/or may be provided with an adhesive, cohesive, sealant material and/or adhesive tape, such as, for example, the first adhesive 16 and/or the second adhesive 20. For example more than one portion of the back side B1 of the first portion 6 and/or the back side B3 of the third portion 10 may be provided or coated with the first adhesive 16 as shown in FIG. 19. The first adhesive 16 on the third portion 10 adheres, connects, attaches and/or fastens the back side B3 of the third portion 10 to the back side B2 of the second portion 8, and the first adhesive 16 on the first portion 6 adheres, connects, attaches and/or fastens the back side B1 of the first portion 6 the front side A3 of the third portion 10.

FIG. 20 illustrates the back side B3 of the third portion 10 of the sheet 5 having been folded onto the back side B2 of the second portion such that the top side A3 of the third portion 10 is exposed and/or adjacent to the back side B1 of the first portion 6. As a result, the second and third portions 8, 10 are connected, attached, adhered and/or secured together by the adhesive 16 and a pocket 50 is formed, produced and/or provided between the back sides B2, B3 of the second and third portions 8, 10, respectively. The pocket 50 formed between the second and third portions 8, 10 is sized shaped and/or configured to at least partially receive, house, store and/or enclose the product 4 and carrier 42 that may sealed in the bag of film 18.

FIG. 21 illustrates the product 4 and carrier 42 sealed in the bag of film 18 being inserted into the pocket 50 formed between the back sides B2, B3 of the second and third portions, respectively. The product 4 and carrier 42 sealed in the bag of film 18 may be inserted into the pocket 50 by hand, by machine or a combination thereof. The dimensions of the pocket 50 and/or the window 14 may be sized, shaped and/or configured such that the product 4 and/or the carrier 42 may be correctly aligned and/or held in a required or predetermined product placement position automatically by insertion into the pocket 50 and/or window 14 of the third portion 10. As a result of the size, shape and/or configuration of the pocket 50 and/or the window 14, the correct alignment and/or holding is achieved automatically as the sealed product 4 and/or carrier 42 are loaded, inserted and/or slid in the pocket 50 formed between the second and third portion 8, 10. The pocket 50 created by folding the third portion 10 onto the second portion 8 may form, create and/or provide a matching lock-fit for the product 4 and/or carrier 42 which may automatically position, secure, enclose, house and/or fix the carrier 42 holding the film wrapped product 4 in a correct or predetermined position as the product 4 and/or carrier 42 are inserted or slid into the pocket 50.

FIG. 22 shows entire lengths of the product 4 and carrier 42, sealed in the bag of film 18, inserted, moved, slid and/or positioned into the pocket 50 formed between the second and third portions 8, 10. As a result, a portion of the back side B2 of the second portion 8 may be exposed below the bottom of the product 4 and/or the carrier 42. One or more portions of the carrier 42 positioned the back sides B2, B3 of the second and third sides 8, 10 connect, attach, secure and/or fix the one or more portions of the carrier 42 to the sheet 5. As a result, the product 4 may be connected, attached, secured to the sheet 5 via the pocket 50 and/or the carrier 42.

FIG. 23 shows the folded assembly 2 after the back side B1 of the first portion 6 has been folded onto the front portion A3 of the third portion 10. As a result, at least portions of the carrier 42 are enclosed, housed, secured and/or encircled in at least portions of the first portion 6 and the second portion 8 and/or the third portion 10. Further, at least portions of the carrier 42 are enclosed, housed and/or secured between the back side B2 of the second portion 8 and at least one of the back sides B1, B3 of the first and third portions 6, 10, respectively. As a result, the carrier 42 is secured to the folded assembly 2 via the portions 6, 8, 10 of the sheet 5. The first adhesive 16 on the back side B1 of the first portion 6 may connect, attach and/or adhere the back side B1 of the first portion 6 to front side A3 of the third portion 10. As a result, the first portion 6 may be connected, attached and/or adhered to the second and/or third portions 8, 10 via the first adhesive 16.

As the first portion 6 is being folded onto the second portion 8, one or more portions of the product 4 may extend through the window 14 and/or away from the front side A1 of the first portion 6. Moreover, one or more portions of the front side A1 of the first portion 6 may display or be provided with indicia 12. One or more portions 6, 8, 10 of the sheet 5 may be folded onto one another or each other by hand or by use of one or more machines, such as, for example, movable element 24. The assembly 2 may then pass through the heat tunnel to remove any film folds and/or wrinkles that may be present in the bag of film 18 that seals the product 4 and/or the carrier 42. Passing through the heat tunnel may also provide a glossy shine or appearance to film 18 sealed around the product 4. In embodiments, a rear card cut out (not shown in the drawing) with perforations and/or score lines may be provided in second portion 8 such that the assembly 2 may be easy opened to facilitate removal of the sealed product 4 and/or carrier 42.

The embodiments shown in FIGS. 19-23 provide significant improvements as to how the sheet 5 and carrier 42 may quickly join together into the proper requested or predetermined product position format, in an easier, faster and much more exact and automatic product positioning process. These embodiments provide adjustments made to the sheet 5 and carrier 42 joining system that offer many more inherent assembly advantages for either hand assemblies, machine assemblies or combinations thereof. These embodiments may be utilized with almost any size or shaped product to be carded and the correct position alignment may automatically be achieve when the assembly 2 and/or carrier 42 are utilized in the presently disclosed manner.

The embodiments shown in FIGS. 19-23 may eliminate the movement of products that may occur in a blister pack without adding extra items or adhesives, which may slow the assembly process. Also with all standard blister packages, the outside edges of blister packages may get “crushed” all around the cards outer edge which may also occur around each product on the blister package. This “crushing” is inherently caused by the standard blister packaging requires sealing process (i.e., time, temperature and pressure) and this “crushing” often happens to each and every blister card currently produced by known blister machines. The card “crushing” which may be totally eliminated along with problems with product movement by the assemblies and processes set forth in the present disclosure. Additionally, improved graphics may be achieved because the present assemblies and processes avoid the use of a blister coating to be applied over the printed artwork.

FIG. 24 shows a back side of a sheet 5 petitioned, cut or scored into three portions 6, 8, 10 and having a window 14 formed in the first portion 6 and the third portion 10, and a product 4 connected, attached, adhered, banded and/or affixed to a carrier 42. The product 4 and carrier 42 are sealed in a bag made of a film material, such as, film 18. The windows 14 may be sized, shaped and/or configured to receive and/or house the product 4 sealed in the bag of film 18. As a result, at least a portion of the product 4 may extend through the windows 14 after the first and third portions 6 and 10 have been folded onto the second portion 8.

One or more portions of the back sides B1, B2 and/or B3 of the first, second and third portions 6, 8, 10, respectively, may be coated with and/or may be provided with an adhesive, cohesive, sealant material and/or adhesive tape, such as, for example, the first adhesive 16 and/or the second adhesive 20. For example, more than one portion of the back side B1 of the first portion 6 and/or the back side B3 of the third portion 10 may be provided or coated with the second adhesive 16 as shown in FIG. 24 for connecting, sealing and/or adhering the first, second and/or third portions 6, 8, 10 together or to one another. The first adhesive 16 may be coated and/or provided on at least one portion of the back side B2 of the second portion 8 and may connect, attach, secure and/or adhere the product 4 and/or the carrier 42 sealed in the bag of film 18 to the second portion 8. The second adhesive 20 on the third portion 10 adheres, connects, attaches and/or fastens the back side B3 of the third portion 10 to the back side B2 of the second portion 8, and the second adhesive 20 on the first portion 6 adheres, connects, attaches and/or fastens the back side B1 of the first portion 6 the front side A3 of the third portion 10. Upon folding the third portion 10 onto the second portion 8 and the first portion 6 onto the third portion 10, the product 4 and carrier 42 may be enclosed, sealed, packaged and/or secured within or between one or more of the first, second and/or third portions 6, 8, 10 of the sheet 5.

In embodiments, the carrier 42 may be sized, shaped and/or configured such that more than one product 4 may be connected, attached, secured and/or adhered to the carrier 42 which may subsequently be sealed in the film 18 (not shown in the drawings). The first and third portions 6, 10 may have more than one window 14 formed therein such that the more than one product 4, connected to the carrier 42, may extend through the more than one widow 14 formed in the first and third portions 6, 10 when the first and third portions 6, 10 may be folded onto the second portion 8.

FIG. 25 shows the product 4 and carrier 42, sealed in the bag of film, have been positioned on or moved onto the back side B2 of the second portion 8 of the sheet 5. As a result, the product 4 and carrier 42 are connected, attached, adhered and/or secured to the back side B2 of the second portion 8 via the first adhesive 16. Also shown in FIG. 25 is the third portion 10 being folding and/or moved towards the back side B2 of the second portion 8. After the back side B3 of the third portion 10 is folded and/or moved onto the back side B2 of the second portion 8, at least portions of the product 4 and/or the carrier 42 may be located, positioned, enclosed and/or secured between the back sides B2, B3 of the second and third portions 8, 10, respectively, as shown in FIG. 26. The back side B3 of the third portion 10 may be connected, attached, adhered and/or secured to the back side B2 of the second portion 8 via the second adhesive 20 on the back side B3 of the third section 10. Further, one or more portions of the carrier 42 may be positioned, located, enclosed and/or surrounded between the one or more portions of the second and third portions 8, 10. Moreover, one or more portions of the product 4 may extend outwardly through the window 14 of the third portion 10 and/or away from the front side A3 of third portion 10 as the third portion 10 is being folded onto the second portion 8 and/or after the second and third portions have been adhered together. Furthermore, the film 18 wrapped around or enclosing the product 4 and the carrier 42 may be pull tighter against or closer to the product 4 and/or the carrier 42 by force applied by the third portion 10 when the third portion 10 is folded onto the second portion 8.

FIG. 27 shows the folded assembly 2 that is formed, produced and/or provided after the back side B1 of the first portion 6 has been folded onto the front side A3 of the third portion 10. After the back side B1 of the first portion 6 is folded and/or moved onto the front side A3 of the third portion 10, at least portions of the product 4 and/or the carrier 42 may be located, positioned, enclosed and/or secured between the back side B2 of the second portion 8 and at least one the back sides B1, B3 of the first and third portions 6, 10, respectively, as shown in FIG. 27. As a result, the back side B1 of the first portion 6 may be connected, attached, adhered and/or secured to the front side A3 of the third portion 10 via the second adhesive 20 on the back side B1 of the first section 6. Further, one or more portions of the carrier 42 may be positioned, located, enclosed, surrounded between the one or more portions of the first portion 6 and at least one second and third portions 8, 10. Moreover, one or more portions of the product 4 may extend outwardly through the window 14 of the first portion 8 and/or away from the front side Alof the first portion 6 as the first portion 6 is being folded onto the third portion 10 and/or after the first and third portions 6, 10 have been adhered together. As a result, at least one portion of the product 4 and/or the carrier 42 are packaged, enclosed, stored and/or secured between at least portions of the first, second and/or third portions 6, 8, 10 to provide the folded assembly 2. One or more portions of the front side A1 of the first portion 6 may display and/or be provided with indicia 12 associated with the product 4. In embodiments, the bond strength between the backside B1 of the first portion 6 and the front side A3 of the third portion may be the same as or greater the bond strength between the backsides B2, B3 of the second and third portions 8, 10, respectively. The adhesive strength of the second adhesive 20 provided on the first portion 6 may be the same as or greater than the adhesive strength of the second adhesive 20 provided on the third portion 10. As a result, folding of the first portion 6 onto the third portion 10 may form, produce and/or provide the folded assembly 2 which is firmly connected, adhered, sealed and/or secured for securely packaging the one or more products 4 therein.

The assembly 2, after being produced or provided by folding the portions 6, 8, 10 onto each other, may then pass through the heat tunnel to remove any film folds and/or wrinkles that may be present in the bag of film 18 that seals the product 4 and/or the carrier 42. Passing through the heat tunnel may also provide a glossy shine or appearance to the film 18 sealed around the product 4. In embodiments, a rear card cut out (not shown in the drawing) with perforations and/or score lines may be provided in the second portion 8 such that the assembly 2 may be easy opened to facilitate removal of the sealed product 4 and/or carrier 42. Loading the product 4 and carrier 42 onto the second portion 8 and/or the folding of the first and third portions 6, 10 onto each other and/or onto the second portion 8 may be accomplished by hand, by one or more machines (i.e., movable element 24), or by combinations thereof.

In embodiments, the sheet 5 may be divided, separated, petitioned, cut, scored and/or foldable into two portions 6, 8 as shown in FIG. 28 or into three portions 6, 8, 10 as shown in FIG. 29. The first portion 6 of the sheet 5 may have at least one window 14 formed through the sheet 5 as shown in FIGS. 28 and 29. The front side A1 of the first portion 6 may display front card indicia 12 as shown in FIG. 1. The product 4 may be connected, attached and/or adhered to the carrier 42 prior to the product 4 and carrier 42 being loaded into the window 14 as shown in FIG. 30. The first adhesive 16 layer and/or the second adhesive layer 20 may be applied to the product 4 and/or the carrier 42 prior to connecting the product 4 and the carrier 42 together. As a result, the first adhesive layer 16 and/or the second adhesive layer may connect, attach and/or adhere the product 4 to the carrier 42 prior to placing the product 4 and carrier 42 in the window 14 of the first portion 6. The product 4 and carrier 42 may be sealed or wrapped in a bag made of the film 18 prior to being into the window 14 of the first portion 6.

The perimeter of the carrier 42 may have a different or substantially different shape, size, configuration and/or dimensions as the perimeter of the window 14 of the first portion and/or as the perimeter of the product 4 as shown in FIG. 30. The product 4 and carrier 42 sealed or wrapped in the bag of film 18 may be manually, or by machine, loaded into the window 14 of the first portion 6. The outer edges of the perimeter of the carrier 42 may extend outwardly and/or away from the window 14 such that the outer edges contact one or more portions of the backside B1 of the first portion 6 when the product 4 and the carrier 42 may be loaded into the window 14 of the first portion 6. After the product 4 and carrier 42 is loaded into the window, the backside B2 of the second portion 8 may be folded onto the backside B1 of the first portion 6 as shown in FIG. 28. As a result, the outer edges of the carrier 42 may be secured, located, positioned, connected and/or attached to one or more portion of the backside B1 of the first portion 6 and/or backside B2 of the second portion 8. Moreover, at least the outer edges of the carrier 42 may be secured within or between the backsides B1, B2 of the first and second portions 6, 8. When the third portion 10 is present as shown in FIG. 29, the backside B3 of the third portion 10 may be folded onto the top side A2 of the second portion 8. After the portions 6, 8, 10 have been folded onto themselves, the first and/or second adhesives 16, 20, provided on at least one of the backsides B1, B2, B3 of the portions 6, 8, 10, may connect, adhere, attach and/or join the portions 6, 8, 10 together to form the assembly 2 as shown in FIG. 1.

The outer edges of the carrier 42 secured between the first and second portions 6, 8 may significantly improve substrate to substrate adhesion between the portions 6, 8, without the film layers 18 getting in the way of a significant card to card sealing between the portions 6, 8. In an embodiment, the product 4 may be fugitive glued to the carrier 42 and overwrapped in a bag of film 18. The top side A1 of the first portion may be feed onto the conveyor belt face down and then may be loaded from behind with the carrier 42 and bagged product 4 loaded into the cutout window 14. Then the other one or two sides may be glued and compression folded over and closed. In an embodiment, the film 18 shown in FIG. 30 is a polyolefin.

In embodiments, the sheet 5 may be divided, separated, petitioned, cut, scored and/or foldable into at least two portions 6, 8 as shown in FIG. 31. The first portion 6 of the sheet 5 may have at least one window 14 formed through the sheet 5 as shown in FIG. 31. The front side A1 of the first portion 6 may display front card indicia 12 as shown in FIG. 1. A pre-formed blister 101 (hereinafter “blister 101”) may be sized and/or shaped to receive the product 4 as shown in FIG. 32. In embodiments, the blister 101 may be made of a rigid or semi-rigid plastic or polymer material. In an embodiment, the blister 101 may be made of recycled polyethylene terephtalate. In embodiments, a flange 102 of the blister 101 may be coated or may receive the first adhesive 16 and/or the second adhesive 20 for adhering the first and second portions 6, 8 together after the backside B2 of the second portion 8 has been folded onto the backside B1 of the first portion 6. In embodiments, the first adhesive 16 and/or the second adhesive 20 may be provided on both sides of the flange 102 of the blister 101.

The product 4 may be loaded into a pocket of the blister 101. The window 14 of the first portion 6 may be sized and/or shaped to receive the product and/or the pocket of the blister 101 as shown in FIG. 33. The first adhesive 16 and/or second adhesive 20 provided on the flange 102 of the blister 101 may connect, attach and/or adhere the blister 101 to the first portion 6 when the blister 101 and the product 4 are loaded into the window 14. The backside B2 of the second portion 8 may be folded onto the backside B1 of the first portion 6. The exposed adhesive on the flange 102 of the blister 101 may connect, attach and/or adhere to the backside B2 of the second portion 8. At a result, the backsides B1, B2 of the first and second portions 6, 8 may be connected, attached and/or adhered to each other via the adhesives on the flange 102 of the blister 101. Moreover, the flange 102 of the blister 101 may be located, positioned and/or secured between the backsides B1, B2 of the first and second portions 6, 8. As a result, the product 4 and/or the blister 101 may be secured between the first and second portions 6, 8 to produce the assembly 2 as shown in FIG. 1. In embodiments, one or more portions of the backsides B1, B2 of the first and second portions 6, 8 may be provided with the first and/or second adhesives 16, 20 which may connect, attach and/or adhere the first and second portions 6, 8 together when the second portion 8 is folded onto the first portion 6.

In embodiments, the sheet 5 may be dispensed onto a conveyor belt, the blister 101 and the product 4 may be placed by hand or machine into the window 14, and then one or more portions of the sheet 5 and/or blister 101 may be glued and folded to produce the assembly 2. As a result, production of assemblies 2 may be at about 100 assemblies to about 450 assemblies per minute. Current blister machine typically cycle, at best, about 20 cycles to about 22 cycles per minute. Moreover, producing the assembly 2 by coating both sides of the flange 102 of the blister 101 may or may not require tooling.

In embodiments, the sheet 5 may be divided, separated, petitioned, cut, scored and/or foldable into at least two portions 6, 8, and the window 14 may be formed in the first portion 6 and covered with the film 18 as shown in FIG. 34. The product 4 may be loaded, by hand or machine, into the window 14, and one or more portions of the backsides B1, B2 of the first and second portions 6, 8 may be glued and folded onto each other to produce the assembly 2 as shown in FIG. 1. In an embodiment, the first adhesive 16 and/or the second adhesive 20 may be provided on one or more portions of the backsides B1, B2 of the first and second portions 6, 8 before the first and second portions 6, 8 are folded onto each other to produce the assembly 2. The product 4 may push, force and/or stretch the film 18 outwardly when the first and second portions 6, 8 are folded onto each other to produce the assembly 2. In embodiments, production of the assemblies 2 may be at about 100 assemblies to about 450 assemblies per minute. As a result, producers and/or manufactures of the assemblies 2 may achieve speeds that are about 5 times to about 7 times faster than typical known blister sealing systems. Moreover, production of the assembly 2 may eliminate “crush” marks from conventional blister packaging. In an embodiment, production of the assembly 2 may not require seal tooling to run or be utilized, which is a significant cost savings to the producer and/or manufacture of the assembly 2.

In embodiments, assemblies 2, 100 may be produced, created, folded and/or sealed via a blister pack machine system 200 (hereinafter “system 200′) as shown in FIGS. 35-41. For example, one or more sheets 5 may be loaded onto the system 200, whereby one or more products 4 and/or blisters 101 (optionally loaded with one or more products 4) may be subsequently loaded, placed, dropped and/or positioned within the one or more windows 14 formed in the one or more sheets 5, by hand or by machine, and the one or more portions 6, 8 and/or 10 of the one or more sheets 5 may be folded onto each other to seal or close the one or more sheets 5 and/or to produce the assemblies 2, 100.

In an embodiment, the system 200 may comprise a body having a total length defined between a first end 204 and a second end 206 and a total width defined between a first side 208 and a second side 210. The system 200 may comprise a plurality of conveyor belts 212 (hereinafter “belts 212”) which may extend along the entire length of the system 200 or at least along a portion of the entire length of the system 200. Each belt 212 may rotate around and/or may encircle one or more box supports 214 (hereinafter “supports 214”) which may physically provide support to the conveyor belt along the entire length of the system 200 or at least along a portion of the entire length of the system 200. The supports 214 may be made of a metal material or a stiff plastic or polymer material. As each belt 212 rotates around the supports 214, the tension or firmness of the belt 212 may remain constant, or substantially constant, as a result of the physical support provided by the supports 214. In embodiments, an inner circumference of each belt 212 may be same as, substantially the same as, or greater than an outer circumference of the all of the supports 214 that support each belt 212.

A plurality of crossbars 216 (hereinafter “crossbars 216”) may extend across the entire width of the system 200 between the first side 208 and the second side 210 (hereinafter collectively known as “sides 208, 210”), as shown in FIGS. 35, 39 and 41. As a result, the sides 208, 210 may be connected, attached and/or fixed to each other via the crossbars 216. The supports 214 are movable connected, attached and/or fixed to the crossbars 216 such that the supports, along with the belts 212, may slide to any position between the sides 208, 210. As a result, the supports 214 and belts 212 are adjustable to any position between the sides 208, 210 such that adjustable cavities 218 (hereinafter “cavities 218”) are provided or formed between the belts 212 as shown in FIG. 35. The cavities 218 may be sized, shaped, configured and/or adapted to receive the one or more products 4 and/or one or more blisters 101 as shown in FIG. 41. In embodiments, the supports 214 and/or belts 212 may be located at a first position to provide a first cavity 218 that is sized and/or shaped to receive products 4 and/or blisters 101 have a first size, a first shape and/or a first depth. Subsequently, the supports 214 and/or belts 212 may be moved to a second position to provide a second cavity 218 that is sized and/or shaped to receive products 4 and/or blister 101 having a second size, a second shape and/or a second depth. Moreover, the first size may be greater than or less than the second size, the first shape may be different than the second shape, and the first depth may be greater than or less than the second depth.

In embodiments, the first end 204 of the system 200 may have loading components 220 (hereinafter “components 220”) which may comprise rollers, bars, platforms and/or the like as shown in FIGS. 35, 38 and 40. The one or more sheets 5 may be loaded onto the belts 212 via the components 220 such that the windows 14 of the sheets 5 may be aligned with or may overlap the cavities 218 formed between the belts 212 and/or the supports 214 as shown in FIG. 41. Thus, when the products 4 and/or the blisters 101 are loaded into the windows 14 of the sheets 5, the products 4 and/or the blisters 101 are positioned or located within the cavities 218 between the belts 212 and/or the supports 214.

In embodiments, one or more trucks or holdown wheels 222 (hereinafter “wheels 222”) may be positioned and/or located along the length of the belts 212 as shown in FIGS. 35-37 and 40. The wheels 222 may comprises rollers or components that maintain or holddown the sheets 5 onto the belts 212 as the sheets 5 move along the belts 212 from the first end 204 to the second end 206 of the system 200. Alternatively or additionally, the vacuum producing device 34 may be incorporated into the system 200 and/or located between the belts 212 and/or within the cavities 218 such that the vacuum provided by the vacuum producing device 34 holds or maintains the sheets 5 in contact with the outer surface of the belts 212 as the sheets 5 move along the length, or portion of the length, of the belts 212. As a result, the sheets 5 may be in substantial contact, or complete contact, with the outer surface of the belts 212 while the sheets move along the entire length, or at least a portion of the entire length, of the belts 212 via the wheels 222 and/or the vacuum producing device 34. The wheels 222 may be movably connected, attached or fixed to the body of the system 200 via one or more rods 224 (hereinafter “rods 224”) and/or one or more arms 226 (hereinafter “arms 226”) as shown in FIGS. 35 and 36. As a result, the wheels 222 may be adjustable via rods 224 and/or arms 226 such that the wheels 222 may be positioned or movable to locations that are adjacent to and/or directly over the outer surface of the adjustable belts 212.

In embodiments, the system 200 may have a first folding mechanism 228 (hereinafter “first mechanism 228”) and/or a second folding mechanism 230 (hereinafter “second mechanism 230”) located adjacent to or near the second end 206 of the system 200. The first mechanism 228 may top fold at least one of the portion 6, 8, 10 of the sheets 5 onto the other portions of the sheets 5 to enclose the products 4 and/or blisters 101 therein and to produce, create and/or form the assemblies 2, 100. The second mechanism 230 may fold at least one of the portions 6, 8, 10 of the sheets 5 sideway onto the other portions of the sheets 5 to enclose the products 4 and/or blister 101 therein and to produce, create and/or form the assemblies 2, 100. In an embodiment, the second mechanism 230 may be shaped as one or more curved or rounded blades that side folds the portions of the sheets 5 onto each other to produce the assemblies 2, 100. As the portions of the sheets 5 are being folded onto each other to form the assemblies 2, 100 via the first mechanism 228 and/or the second mechanism 230, adhesives, cohesion, pressure and/or heat from a heat tunnel seal the portions of the sheets 5 together such that the products 4 and/or the blisters 101 are enclosed therein and/or protected from subsequent tampering and/or environmental conditions. After sealing, the assemblies 2, 100 may be removed from the belts 212 and/or the system 200 for shipping and/or distribution.

It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems and/or methods. Also, various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, and are also intended to be encompassed by the present disclosure. 

1. A method for packaging retail products, the method comprising: providing a sheet divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet; loading a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the at least one window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the at least one window formed in the sheet; and folding the second part of the sheet onto the first part of the sheet to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.
 2. The method according to claim 1, wherein the method has a blister product assembly production rate from about 100 assemblies/minute to about 450 assemblies/minute.
 3. The method according to claim 1, wherein the sheet is made of paper-based materials, plastic or polymer-based materials or a combination thereof.
 4. The method according to claim 1, wherein the pre-formed blister is made of a rigid or semi-rigid plastic.
 5. The method according to claim 1, wherein the pre-formed blister is made of at least one polymer material.
 6. The method according to claim 1, further comprising: coating an adhesive onto one or more sides of a flange of the pre-formed blister before the pre-formed blister is loaded into the at least one window formed in the sheet.
 7. The method according to claim 6, further comprising: adhering the first and second parts of the sheet together, via the adhesive coated onto one or more sides of the flange of the pre-formed blister, when, or after, the second part is folded onto the first part of the sheet.
 8. The method according to claim 1, further comprising: adhering the first and second parts of the sheet together via cohesion or an adhesive when, or after, the second part is folded onto the first part of the sheet to produce the blister product assembly.
 9. The method according to claim 1, further comprising: dispensing the sheet onto a conveyor belt prior to loading the pre-formed blister into the window formed in the sheet.
 10. The method according to claim 1, further comprising: placing the pre-formed blister, by hand or by machine, into the window formed in the sheet for loading the pre-formed blister into the window.
 11. The method according to claim 1, wherein the second part of the sheet has a window formed therein for receiving at least a portion of the pre-formed blister and/or a portion of the at least one retail product.
 12. A method for packaging retail products, the method comprising: positioning a sheet on a conveyor belt system comprising an adjustable cavity, wherein the sheet is divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet, wherein the at least one window formed in the sheet is located above the adjustable cavity of the conveyor belt system when the sheet is positioned on the conveyor belt system; loading a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the at least one window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the at least one window formed in the sheet and into the adjustable cavity of the conveyor belt system; and folding the second part of the sheet onto the first portion to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.
 13. The method according to claim 12, further comprising: adjusting a width and/or depth of the adjustable cavity of the conveyor belt system to correspond to dimensions of the at least one retail product and/or the preformed blister prior to loading the pre-formed blister into the at least one window formed in the sheet.
 14. The method according to claim 12, further comprising at least one selected from: providing downward vacuum holding forces onto the sheet by a vacuum producing device of the conveyor belt system after the sheet is positioned on the conveyor belt system; and providing downward vacuum holding forces onto the at least one retail product by the vacuum producing device after the at least one retail product is loaded into the at least one window formed in the sheet.
 15. The method according to claim 12, wherein the method has a blister product assembly production rate from about 100 assemblies/minute to about 450 assemblies/minute.
 16. The method according to claim 12, further comprising: coating an adhesive onto one or more sides of a flange of the pre-formed blister before the pre-formed blister is loaded into the window formed in the sheet.
 17. The method according to claim 16, further comprising: adhering the first and second parts of the sheet together, via the adhesive coated onto one or more sides of the flange of the pre-formed blister, when, or after, the second part is folded onto the first part of the sheet.
 18. The method according to claim 1, further comprising: adhering the first and second parts of the sheet together via cohesion or an adhesive when, or after, the second part is folded onto the first part of the sheet to produce the blister product assembly.
 19. The method according to claim 1, further comprising: placing the pre-formed blister, by hand or by machine, into the window formed in the sheet for loading the pre-formed blister into the window.
 20. The method according to claim 1, wherein the second part of the sheet has a window formed therein for receiving at least a portion of the pre-formed blister and/or a portion of the at least one retail product. 